Method of making a dual durometer self-locking and sealing plug

Claim 1

A continuous method for making a self-locking and sealing plug for filling and sealing an opening in a panel comprising: (1) providing progressive injection molding means having a pair of injection units, (2) providing in the first of said units a molten thermoplastic resin-based polyolefin material having a durometer hardness reading at ambient temperature of about 60 to about 110 Rockwell R, (3) providing in the second of said units a molten thermoplastic electomeric material consisting of a blend of thermoplastic crystalline polyolefin resin and cured monoolefin copolymer rubber and having a durometer reading at ambient temperature of about 65 Shore A to about 50 Shore D, (4) providing first and second mold means having multi-cavities respectively and relatively movable between open positions and two alternate closed molding positions, (5) configuring said cavities of said first mold means and at least one of said cavities of said second mold means to cooperate and provide a first complete mold cavity when said mold means are at either of said closed molding positions to form an opening-filling portion of said plug upon injection of said molten thermoplastic material from said first injection unit into said first complete mold cavity, (6) configuring at least one other of said cavities of said second mold means to cooperate with said cavities of said first mold means and provide a second complete mold cavity shaped when said mold means are at either of said closed molding positions and a hardened opening-filling portion of said plug is within the cooperating cavity of said first mold means to form a sealing portion of said plug having portions in intimate contact with portions of said opening-filling portion upon injection of said molten thermoplastic material from said second injection unit into said second complete mold cavity, (7) heating said thermoplastic material in said first unit to a temperature within a range of about 380° F. to 390° F., and heating said thermoplastic material in said second unit to a temperature within a range of about 375° F. to 390° F., (8) moving said mold means to one of said closed molding positions, (9) injecting thermoplastic material from said first unit into said first complete mold cavity to form an opening-filling portion, (10) cooling said first complete mold cavity, (11) moving said mold means to their open positions, (12) while retaining the opening-filling portion within the cavity of said first mold means, simultaneously moving said mold means and said opening-filling portion within the last named cavity to the other of said closed molding positions, (13) simultaneously injecting said heated thermoplastic materials from said first and second units into said first and second complete mold cavities respectively to form an opening-filling portion and a molded part in said first and second complete mold cavities respectively, (14) cooling said mold means to partially harden said thermoplastic materials therein and to cool said opening-filling portion in said first complete mold cavity to a temperature within a range of about 325° F. to about 335° F.; (15) moving said mold means to their open positions, (16) ejecting the partially hardened part formed in said second complete mold cavity, (17) while retaining the partially hardened opening-filling portion within the cavity of said first mold means that cooperated to form said opening-filling portion, simultaneously moving said mold means and said opening-filling portion at said cooled temperature within the last named cavity to the other of said closed molding positions, (18) repeating steps (13)-(17), thereby in accordance with injection of said molten materials into said first and second complete mold cavities per step 13, to units and bond said opening-filling portion with a sealing portion of said plug formed in said second complete mold cavity and simultaneously to form another opening-filling portion of said plug in said first complete mold cavity.